Operation Manual

2012

®DEUTZ

• Please read and observe the informationgiven in this Operation Manual. This willenable you to avoid accidents, preservethe manufacturer's warranty and maintainthe engine in peak operating condition.

• This engine has been built exclusively forthe application specified in the scope ofsupply, as described by the equipmentmanufacturer and is to be used only for theintended purpose. Any use exceeding thatscope is considered to be contrary to theintended purpose. The manufacturer willnot assume responsibility for any damageresulting therefrom. The risks involved areto be borne solely by the user.

• Use in accordance with the intended pur­pose also implies compliance with the con­ditions laid down by the manufacturer foroperation, maintenance and servicing. Theengine should only be operated by person­nel trained in its use and the hazardsinvolved.

• The relevant accident prevention gUidelinesand other generally accepted safety andindustrial hygiene regulations must be ob­served.

• When the engine is running, there is a riskof injury through:- turning/hot components- engines with positive ignition- ignition systems (high electrical voltage)You must avoid contact at all times!

• Unauthorized engine modifications will in­validate any Iiability clai ms against the manu­facturer for resultant damage.Manipulations ofthe injection and regulatingsystem may also influence the performanceofthe engine, and its emissions. Adherenceto legislation on pollution cannot be guaran­teed under such conditions.

• Do not change, convert oradjust the coolingair intake area to the blower.The manufacturer shall not be held respon­sible for any damage which results fromsuch work.

• When carrying out maintenance/repair op­erations on the engine, the use of DEUTZoriginal parts is prescribed. These arespecially designed for your engine andguarantee perfect operation.Non-compliance results in the expiry of thewarranty!

• Maintenance and cleaning of the engineshould only be carried out when the engineis switched off and has cooled down.You must ensure that the electrical syste mshave been switched off and the ignitionkey has been removed.Accident prevention guidelines concerningelectrical systems (e.g. VDE-01 00/-01 01/-0104/-0105 Electrical protective measuresagainst dangerous touch voltage) are to beobserved.When cleaning with fluids, all electricalcomponents are to be covered impermeably.

Engine Serial ITIIIIJJNumber:

Please enter the engine serial number here. Thisnumber should be quoted when inquiring aboutCustomer Service, Repairs or Spare Parts (seeSection 2.1).

Technical modifications required to improve ourengines are reserved with regard to specificationdata and other technical information contained inthis Operation Manual. No parts of this Manualmay be reproduced in any form or by any meanswithout our written approval.

Operation Manual

2012

02979912 en

®DEUTZ

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Foreword

Dear Customer,

Liquid-cooled DEUTZ engines are designedfor a large number of applications. Conse­quently, a wide range ofvariants are offered tomeet the requirements of specific cases.

Your engine is appropriately equipped for theinstallation concerned, which means that notall of the components described in this Opera­tion Manual are necessarily mounted to yourengine.

We have endeavored to highlight any differ­ences so that you will be able to locate theoperating and maintenance instructions rel­evant to your engine quickly and easily.

Please read this Manual before starting yourengine, and always observe the operatingand maintenance instructions.We are available to help with any additionalinquiries

Sincerely,

DEUTZ AG

1©\31493101

Index

1. General 3.2.1 Electric Starting 6.1.1 Oil Change Intervals3.3 Monitoring Operation 6.1.2 Check Oil Level, Change Engine Oil

2. Engine Description 3.3.1 Engine Oil Pressure 6.1.3 Replace Oil Filter

2.1 Model3.3.2 Coolant Temperature 6.1.4 Clean/Replace Oil Filter (Cup)

2.1.1 Rating Plate3.4 Shutting off 6.2 Fuel System

2.1.2 Position of the Rating Plate3.4.1 Mech. Stopping 6.2.1 Replace Fuel Filter

2.1.3 Engine Serial Number3.4.2 Electr. Stopping 6.2.2 Clean / Replce Fuel Oil Filter (Cup)

2.1.4 Cylinder Enumeration3.5 Operating Conditions

2.2 Engine Illustrations3.5.1 Winter Operation 6.2.3 Clean / purge or change fuel Fuel

2.2.1 Operating Side 20123.5.2 High Ambient Temperature, High Alt- pre-filter

Ribbed V-belt Driveitude 6.2.4 Bleed Fuel System

2.2.2 Starter Side 2012with Fuel Pre-filter

Ribbed V-belt Drive4. Operating Media 6.2.5 Bleed Fuel System

2.2.3 Operating Side 2012 4.1 Lube Oil without Fuel Pre-filter

2.2.4 Starter Side 2012 4.1.1 Quality 6.2.6 Clean/Replace Fuel Pre-Filter, Filter

2.3 Lube Oil Circuit Schematic 4.1.2 Viscosity Element

2.3.1 Lube Oil Plan 4.2 Fuel 6.2.7 Clean/Replace/VentFuel Pre-Filter,

2.4 Fuel System 4.2.1 Quality Filter Element

2.4.1 Fuel System Plan 4.2.2 Winter Fuel 6.3 Cooling System

2.5 Coolant System 4.3 Coolant 6.3.1 Cleaning Intervals

2.5.1 Coolant Plan 2012 4.3.1 Water Quality for Coolant 6.3.2 Clean Cooling System

4.3.2 Coolant Treatment 6.3.3 Drain Cooling System

3. Engine Operation 4.3.3 Cooling System Protectants 6.3.4 Fill / Bleed Cooling System

3.1 Commissioning6.4 Combustion Air Filter

3.1.1 Pour in Engine Oil5. Routine Maintenance 6.4.1 Cleaning Intervals

3.1.2 Filling Oil Bath Air Filter with Engine 5.1 Maintenance Plan 6.4.2 Emptying Cyclone Type Precleaner

Oil 5.2 Maintenance Diagram 6.4.3 Clean Oil Bath Air Filter

3.1.3 Pour in Fuel 5.3 Maintenance Work Completed 6.4.4 Dry Type Air Cleaner

3.1.4 Fill / Bleed Cooling System6.5 Belt Drives

3.1.5 Other Preparations 6. Service and Maintenance 6.5.1 Check V-belts

3.2 Starting 6.1 Lubrication System- 2012 Standard

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- 2012 with Ribbed V-belt 00N@

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Index

6.5.2 Tension V-belts 7. Faults, Causes and RemediesCoolant / Fuel Pump 7.1 Fault Table

6.5.3 Replace V-beltsCoolant / Fuel Pump 8. Engine Preservation

6.5.4 Replace V-belts 8.1 PreservationRibbed V-belts

6.5.5 Tensjon Alternator V-belts 9. Technical Specification6.5.6 Replace Alternator V-belts6.5.7 Wedge rib V-belts wear limit examine6.6 Adjustments 9.1 Engine Specifications and Settings

6.6.1 CheckValveClearance(Adjust ifNeces- 9.2 Screw Tightening Torques

sary) 9.3 Tools

6.6.1.1 Valve Clearance Adjustment Plan6.7 Accessories 10. Service6.7.1 Battery6.7.2 Rotary Current Alternator6.7.3 Transportation Shackles

DEUTZ Diesel Engines

are the product of many years of research anddevelopment. The resulting know-how, cou­pled with stringent quality standards, guaran­tee their long service life, high reliability andlow fuel consumption.It goes without saying that DEUTZ DieselEngines meet the highest standards for envi­ronmental protection.

Beware of Running Engine

Care and Maintenance

Sound care and maintenance practices will en­sure that the engine continues to meet the re­quirements placed on it. Recommended serviceintervals must be observed and service andmaintenance work carried out conscientiously.Special care should be taken under abnormallydemanding operating conditions.

Safety

General

Service

Please contact one of our authorized servicerepresentatives in the event of breakdowns orfor spare parts inquiries. Our trained special­ists will carry out repairs quickly and profes­sionally, using only genuine spare parts.Original parts from DEUTZ AG are alwaysproduced in accordance with state-of-the-arttechnology.Please turn to the end of this manual for furtherservice information.

Asbestos

I

Shut the engine down before carrying out mainte­nance or repair work. Ensure that the enginecannot be accidentally started. Risk of accidents.When the work is complete, be sure to refit anypanels and guards that may have been removed.Never fill the fuel tank while the engine is running.Observe industrial safety regulations when run­ning the engine in an enclosed space or under­ground.

&This symbol is used for all safetywarnings. Pleasefollowthemcare-

.' .. fully. The attention of operating• personnel should be drawn to

these safety instructions. Generalsafety and accident prevention

regulations laid down by law must also be ob­served.

DEUTZ original parts areasbestosfree.

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Engine Description

2.1 Model2.2 Engine Illustrations2.3 Lube Oil Circuit Schematic2.4 Fuel System2.5 Coolant System

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Engine Description

I 2.1.1 Rating Plate

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The model A, the engine serial number Bandthe performance data are stamped on therating plate.The model and engine serialnumber must be given when ordering parts.

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2.1.2 Position of the Rating Plate

The rating plate C is attached to the crankcase.

2.1 Model

2.1.3 Engine Serial Number

The engine serial number is stamped on thecrankcase (arrow) as well as the rating plate.

2.1 Model

2.1.4 Cylinder Enumeration

Cylinders are numbered consecutively, be­ginning at the flywheel.

Engine Description

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Engine Description

!II 2.2.1 Operating Side 2012III Ribbed V-belt drive

2.2 Engine Illustration

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1 Alternator2 Oil filler3 Coolant connection compensation line4 Fan pulley5 Fuel pump6 Coolant pump7 Ribbed V-belt pulley on crankshaft8 Tension roller9 Feet

10 Oil pan11 Oil filler neck12 Oil filter housing with engine oil cooler13 Oil dipstick14 Optional attachment of:

Compressor or hydraulic pump15 Fuel filter cartridge16 Oil filter cartridge17 Tractive electromagnet

2.2 Engine Illustration

2.2.2 Starter Side 2012Ribbed V-belt drive

Engine Description

18 Turbocharger19 Engine suspension20 Speed regulator21 Flywheel22 SAE housing23 Starter24 Exhaust manifold25 Coolant inlet26 Heater flange not shown27 Thermostat housing coolant outlet

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Engine Description

12.2.3 Operating Side 2012

2.2 Engine Illustration

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1 Turbocharger2 Heater flange3 Fan4 Alternator5 V-belt pulley on crankshaft6 Coolant pump7 Fuel pump8 Oil filler9 Oil filter housing with engine oil cooler

10 Oil filter housing with oil filter cartridge11 Oil dipstick12 Fuel filter13 Tractive electromagnet14 Oil filler neck

2.2 Engine Illustration

2.2.4 Starter Side 2012

Engine Description

15 Engine suspension16 Speed regulator17 Flywheel18 SAE housing19 Oil pan20 Starter21 Feet22 Alternator23 Coolant inlet24 Exhaust manifold25 Coolant outlet

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Engine Description

I 2.3.1 Lube Oil Plan

2.3 Lube Oil Circuit Schematic

18 20 19 16 17 15 21

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©22 23 1

11 12

7 6

5

2 4.2 4.3 4.1 3

1 Oil pan2 Intake line3 Lube oil pump4 Lube oil cooler

4.1 Heat exchanger bypass valve4.2 Shut-off valve4.3 Lube oil replacement filter4.4 Oil pressure sensor

5 Main oil pipe6 Crankshaft bearing7 Con-rod bearing8 Camshaft bearing9 Line to spray nozzle

10 Spray nozzle for piston cooling11 Valve lifter with rocker arm impulse lubrica-

tion12 Stop rod, oil supply for rocker arm lubrication13 Rocker arm14 Return line to oil pan15 Oil line to turbocharger16 Turbocharger17 Oil line to compressor or hydraulic pump18 Compressor19 Hydraulic pump20 Return line from compressor or hydraulic

pump21 Line to the differential (2x)22 Balancer shafts23 Turbocharger return to crankcase

2.4 Fuel System

2.4.1 Fuel System Plan

Engine Description

1 Fuel tank2 Line to fuel pump3 Fuel pump4 Line to fuel filter5 Fuel filter6 Line to the injection pumps7 Injection pump8 Line to injection valve9 Injection valve

10 Banjo boltwith pressure maintenancevalve11 Return line to fuel filter housing from

pressure maintenance valve(with cup filter installation only)

12 Return line to fuel tank13 Maintain maximum possible distance

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Engine Description

!II 2.5.1 Coolant block diagram 2012iii Example: With cup filter

2.5 Coolant System

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1. Thermostat housing2. Outlet neck cover3. Coolant pump4. Lube oil cooler5. Cylinder cooling6. Cylinder head cooling7. Line from engine to heat exchanger8. Heat exchanger9. Line from heat exchanger to thermostat10. Ventilation line to the compensation tank11. Compensation tank12. Coolant compensation line13. Coolant return from heater14. Coolant supply to heating at V-belts15. Coolant supply to heating at ribbed

V-belts

3.1 Commissioning3.2 Starting3.3 Monitoring Operation3.4 Shutting off3.5 Operating Conditions

Engine Operation

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Engine Operation

II 3.1.1 Pour in Engine Oil

As a rule, engines are delivered without oil.Pour lube oil into the oil filler neck (arrow).Oil capacity, see 9.1.For oil grade and viscosity, see 4.1.

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3.1.2 Oil Bath Air Filter withEngine Oil

FUEL

Fill oil cup 1 of the oil bath air cleaner (ifinstalled) with oil up to the arrow.For oil grade and viscosity, see 4.1.

~Never fill the fuel tank while the

, engine is running. Ensure clean-• liness! Do not spill fuel!

3.1 Commissioning

3.1 Commissioning

3.1.3 Filii Bleed Cooling System

• 2012: In accordance with the radiator suppli­er's specifications

• Unit engine: In accordance with the radiatorsupplier's specifications

3.1.4 Other Preparations

• Check battery and cable connections, see6.7.1 .

• Trial run-After the engine has been prepared, carry outa brieftrial run for approx. 10 minutes, withoutload if possible.

During and after the trial run- Check the engine for leaks.

After the engine has been turned off- Check oil level and top up if necessary,

see 6.1.2.- Retension V-belts, see 6.5.

• Breaking inDuring the break-in phase - about 200 operat­ing hours - check the oil level twice a day.After the engine is broken in, checking once aday will be sufficient.

• In the event of commissioning engineswhich have been preservedCarry out removal of preservation in accord­ance with Chapter 8.1.

Engine Operation

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Engine Operation

II 3.2.1 Electric Starting

&Before starting, make sure thatnobody is standing in the im-

,. mediate vicinity of the engine• or driven machine.

After repair work:Check that all guards have

been replaced and that all tools have beenremoved from the engine.When starting with glow plugs, do not use anyother starter substance (e.g. injection withstart pilot). Risk of accident!Caution: If the speed regulator has beenremoved, the engine must not be startedunder any circumstances.Disconnect the batteryl

Do not actuate the starter for more than 20seconds. Ifthe engine does notcatch, waitforone

C") minute then try again.o If the engine does not catch after two attempts,~ refer to the Fault Table (see 7.1).@

• Disengage the clutch to separate the en­gine from any driven parts.

• Bring speed adjustment lever 1 into at leastthe middle speed position in the direction ofthe arrow.

• Move cut-out handle 2 into operating posi­tion counter to the direction of the arrow.

3.2 Starting

without cold start assistance

• Insert key- Position 0 = no operating voltage.

• Turn key clockwise- Position 1 =operating voltage- Pilot lights 1 and 2 illuminate.

• Push key in and turn further clockwiseagainst spring pressure.- Position 2 = no function- Position 3 =start

• Release key as soon as engine fires- The pilot lights will go out.

3.2 Starting

with cold start assistanceHeater flange

1©12574612

• Insert key- Position 0 =no operating voltage.

• Turn key clockwise- Position 1 =operating voltage.- Pilot lights illuminate, pre-glowing untilglow indicator is extinguished.

• Push key in and turn further clockwiseagainst spring pressure.- Position 2 =no function- Position 3 =start

• Release key as soon as engine fires.- The pilot lights will go out.

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Engine Operation

3.3.1 Engine Oil Pressure

Oil pressure lamp

1<91 25 752 11

• The oil pressure pilot light comes on withoperating voltage on and engine off.

• The oil pressure pilot light must be extin­guished when the engine is running.

Oil Pressure Indicator

• The pointer must remain in the green sectorover the entire operating range.

3.3 Monitoring Operation

Oil Pressure Gauge

• The pointer of the oil pressure gauge mustdisplay the minimum oil pressure (see 9.1)

3.3 Monitoring Operation

3.3.2 Coolant temperature

• The engine temperature gauge pointershould always remain in the green sector. Itshould rarely enter the yellow-green sector.If the pointer enters the orange sector, theengine is overheating.Turn off and establish the cause from theFault Table (see 7.1).

Engine Operation

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Engine Operation

II 3.4.1 Mechanical Stopping 3.4.2 Electrical Stopping

3.4 Shutting Off

• Move speed adjustment lever 1 to low idle.

• Move shut-off lever2 until the engine comesto a stop. The charge pilot light and the oilpressure pilot light illuminate when the en­gine stops.

• Turn key counterclockwise (to position 0)and remove. The pilot lights will go out.

8 If possible, do not switch off the engine when~ under full load. Subsequently allow the en­@ gine to idle for approx. 2 mins.

• Turn key counterclockwise (to position 0)and remove. The pilot lights will go out.

3.5 Operating Conditions

3.5.1 Winter Operation

• Lube Oil Viscosity- Select the oil viscosity (SAE grade) according

to the ambient temperature before startingthe engine, see 4.1.2.

- Increase oil change frequency when operat­ing below -10°C, see 6.1.1.

• Diesel Fuel- Use winter-grade diesel fuel for operation

below 0 °C, see 4.2.2.

• Coolant- Mixture ratio of anti-freeze / water for mini-

mum temperature (max. -35°C),see 4.3.1.

• Additional Maintenance Work- Drain the sludge from the fuel tank once a

week (undo the sludge drain screw).-If necessary, adjust oilbath tilter oil level,

like the engine oil, to the ambient temperture.- Below -20°C, after removing the starter ifnecessary, smear the ring gear on the fly­wheel via the pinion bore from time to timewith cold-resistant grease. (e.g. Boschgrease FT 1 V 31).

• Cold Start Assistance-The heaterflange isautomatically initialised at

temperatures < -25°C.

• Battery- Efficient cold starting necessitates that

the battery is well-charged, see 6.7.1.-The starting limit temperatures can be low­

ered by 4-5 °C by heating the bat­teryuptoabout20 °C. (To do so, remove thebattery and store in a warm place).

Engine Operation

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Engine Operation

I 3.5.2 High Ambient TemperatureHigh Altitude

• Air density decreases as altitude or ambi­ent temperature increase.As a result of this, the engine's maximumoutput, the quality of the exhaust gas, thetemperature level and, in extreme cases,starting behaviour, are impeded.In the event of non-stationary operation,use up to altitudes of 1000 m and tempera­tures of 30°C is permissible.If the engine is to operate under unfavour­able conditions (at higher altitudes or tem­peratures), it will be necessary to reducethe injected fuel quantity and thus, enginepower.

• If you have any doubts about engine opera­tion under these or similar conditions, askyour engine or equipment supplier whetherthe engine has been derated in the inter­ests of reliability, service life and exhaustgas quality (smoke!). Otherwise contactyour service representative.

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3.5 Operating Conditions

4.1 Lube Oil4.2 Fuel4.3 Coolant

Operating Media

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Operating Media

I 4.1.1 Quality Grade

Lube oils are differentiated by Deutz accordingto their performance and quality class. Oils ofother, comparable specifications can be used.

Approved oils:

Deutz DOC I DOC II DOC III

ACEA E2-96 E3/96/E5-02 E4-99

API CF/CF-4 CH-4/CG-4 -DHD - DHD-1 -

The precise assignment of the admissibleoil qualities to the engines is indicated inchapter 6.1.1.If in doubt, contact your service represen­tative.

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4.1.2 Viscosity

Generally, multi-grade oils shall be used. Inclosed heated rooms at temperatures >5°C,also single-grade oils can be used.

As the viscosity of lube oil is dependent ontemperature, the choice of SAE grade shouldbe governed by the ambient temperatureprevailing at the engine operating site.Optimum operating behaviour will be attainedif you take the accompanying oil viscositydiagram as a guide.Should the temperature fall temporarily belowthe limits of the SAE grade selected, coldstarting may be affected but the engine willnot be damaged.In order to keep wear to a minimum, do notexceed application limits for extended periodsof time.

Synthetic lube oils feature an improvedtemperature and oxidation stability.

4.1 Lube Oil

.1~ ~ ~ l ~~ ~~

30~ l ~~ ~ ~

25

20

15 -0LC')

10 - ~0

1-0C\IVW

~ «5 LC') I-

en.... -W

P""-«ooe 0"--~en ....~o -cr V

I

-5 roo-- - ...- ...- 3= 3= "f- Of- 00 0 0 0 .... ....('I) v ('I) v w W

I I I I

~ «-10 3=f- 3= 3= 3= f-(J)

f-- I---0 0 LC') LC') ~ -w w w w« « « «

"-15 enf- en(J) en--I- _ ... ...

-20~ , ,,

-25

-30~, ~ ,

,, , Only with preheating~

4.1 Lube Oil

4.1.2.1 Specific lube oildefinitions

Turbocharged engines with uprated power andengines with high loadingThe oils listed in enclosure 1 are to be usedfor the following engines and applications:COM/EPA II version and increased outputBF4M 2012/C > 95 kWBF6M 2012/C > 143 kW (bore 101 + 98-MVS)BF6M 2012/C > 135 kW (bore 98 mech. FIE)• all engines in CHP plants• all engines in gensets operating in parallel with

the mains/with each other• engines in combines with:These are high-grade oils according to ACEA orAPI. In addition most of these oils are partlysynthetic, some even fully synthetic (5W-40) andthus achieve the thermal stability required for therelevant application and are distinguished by alowtendencytocausedeposits in the turbochargerand in the charge air pipes with closed-circuitcrankcase breather

Operating Media

Lube oils for engines with uprated power and engines with high loadingProducer Type of lube oil SAE class AvailabilityDEUTZ TXL-10W40 FE 10W-40AGIP Agip Sigma Ultra TFE 10W-40 worldwideAGIP Autol Valve Ultra FE 10W-40 GermanyARALGmbH Aral MegaTurboral 10W-40 worldwideARALGmbH Aral SuperTurboral 5W-30 worldwideBAYWA BayWa Super Truck 1040 Me 10W-40 South GemanyBAYWA BayWa Turbo 4000 10W-40 South GemanyCastrol GmbH Castrol SYNTRUCK 5W-40 Europe, North America, Brazil

Argentina, Australia, South AfricaCastrol GmbH Castrol DYNAMAX 7,5W-40 Europe, North America, Brazil

Argentina, Australia, South AfricaCHEVRON Chevron Delo 400 Synthtic 5W-40 North AmericaESSO Essolube XTS 501 10W-40 EuropeFINA FINA KAPPA FIRST 5W-30 EuropeFINA FINA KAPPA ULTRA 10W-40 EuropeFUCHS DEA DEA Cronos Synth 5W-40 Germany, EuropeFUCHS DEA DEA Cronos Premium LD 10W-40 Germany, EuropeFUCHS DEA Fuchs Titan Cargo MC 10W-40 worldwideFUCHS DEA Deutz Oel TLL 10W-40 MB 10W-40 GermanyFUCHS DEA DEA Cronos Premium FX 10W-40 EuropeFUCHS DEA Fuchs Titan Unic Plus MC 10W-40 worldwideMOBILOIL Mobil Delvac 1 SHC 5W-40 Europe, SE Asia, AfricaMOBIL OIL Mobil Delvac 1 5W-40 worldwideMOBILOIL Mobil Delvac XHP Extra 10W-40 Europe, SE AsiaBP OIL Internationc I BP Vanellus HT Extra 10W-40 EuropeShell International Shell Myrina TX / 5W-30 Europe, different

Shell Rimula Ultra description in some countriesShell International Shell Myrina TX / 10W-40 Europe, different

Shell Rimula Ultra description in some countriesTOTAL TOTAL RUBIA TIR 86000 10W-40 worldwideSchmier61raffinerie Wintershall TFG 10W-40 EuropeSalzbergen GmbHThe table will be extended as and when reqUired.

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Operating Media

14.2.1 Quality

Use commercially available diesel fuel withless than 0.5 0/0 sulphur content. If the sulphurcontent is higher, oil change intervals shouldbe reduced (see 6.1.1).

The following fuel specifications / standardsare approved:

• DIN EN 590

• BS 2869: A1 and A2(with A2, take note of the sulphur content!)

• ASTM D 975-88; 1-D and 2-D

• NATO Code F-54 and F-75

Exhaust emission values which may bedetermined in the case of type approval testsalways refer to the reference fuel prescribedby the authorities for the type approval test.

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4.2.2 Winter Fuel

Waxing may occur at low temperatures,clogging the fuel system and reducing engineefficiency. Use winter-grade diesel fuel (up to-20°C) for operation below 0 °C. This is madeavailable within good time by filling stationsprior to the start of the winter season.

• Kerosene must be added at temperaturesbelow -20°C. The relevant percentagesare given in the adjacent diagram.

• Special diesel fuels may be used in arcticclimatic zones up to -44 °C.

If summer-grade diesel fuel must be used attemperatures below 0 °C, up to 600/0 kerosenecan be added (see diagram).

In most cases, adequate resistance to coldcan be obtained by adding a flow improver(additive). Please ask your DEUTZ partner.

& Diesel fuels must never bemixed with gasoline! (Normal and Super grades)!

4.2 Fuel

+32 0

+23 - 5

+14 -10

+ 5 -15

- 4 - 20

-13 - 25

- 22 - 30

t t 10 20 30 40 50of ac 0~A

Legend:

I Summer-grade diesel fuel

II Winter-grade diesel fuel

A Ambient temperature

B Percentage of kerosen added

&Mix in tank only! Fill with the

'

appropriate amount ofkerosene• first, then add the diesel fuel.

4.3 Coolant

4.3.1 Quality of Water forCoolant

The values listed below must not be exceeded.In orderto examine the qualityofyourwater, a testcase can be ordered from DEUTZ under OrderNo. 12130382.

Water quality min. max.

pH value at 20°C 6.5 8.5

Chloride ion content [mg / dm3] - 100

Sulphate ion content [mg / dm3] - 100

Total hardness [OdGH] 3 20

4.3.2 Coolant Treatment

In the case of liquid-cooled engines, specialattention must be paid to the treatment andcontrol of the coolant, as the engine mayotherwise become damaged as a result ofcorrosion, cavitation and freezing.The treatment of the coolant is carried out byadding a cooling system protectant to thecooling water.The cooling system must be continuously moni­tored, see 5.1. In addition to checking thecoolant level, this also involves checking theconcentration ofthe cooling system protectant.The cooling system protectant concentrationcan be checked with commercially availabletesters (example: gefo glycomat ®).

Operating Media

4.3.3 Cooling SystemProtectants

DEUTZ cooling system protectant must be pur­chased in drums under Order No. 01011490 (5litres) or 1221 1500 (210 litres). These are nitrite,amine and phosphate-free, and provide effectiveprotection against corrosion, cavitation and freez­ing.Ifthe above mentioned cooling system protectantis unavailable, the following products may beused in exceptional cases.

Manufacturer Product designation

AVIA AVIA Antifreeze ExtraARAL Antifreeze ExtraBASF Glysantin G48DEA DEA Radiator Antifreeze

SHELL SHELLGlycoShel1

Thecooling system protectant in thecoolantshouldnotfall beloworexceedthefollowing concentration:

Cooling system protectant Water

max. 45 Vol.% 55%min. 35 Vol.% 65%

Filling volume, see chart over page in combina­tion with specifications in Chapter 9.1.The use of other cooling system protectants, e.g.chemical anti-corrosion agents, is possible inexceptional cases. Consult DEUTZ Service.

I

If nitrite-based cooling systemprotectants are mixed withamine-based agents, danger­ous nitrosamines are formed. A Cooling system protectants must ('f)

, be disposed of in an environmen- 0

• tally-friendly manner. ~@

Operating Media 4.3 Coolant

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Cooling system protection

Coolingcontent of coolant system *)

Frost [Litres]system protectionprotection 18 20 22 25 27 30 32 35

in in[ °C] Cooling system protectant

35 -22 6,3 7,0 7,7 8,75 9,5 10,5 11,2 12,3

40 -28 7,2 8,0 8,8 10 10,8 12 12,8 14

45 -35 8,1 9,0 9,9 11,3 12,2 13,5 14,4 15,8

*) For coolant content of your engine, see Operation Manual Chapter 9.1.Note: Grey sector only after consulting head office

Routine Maintenance

5.1 Maintenance Schedule5.2 Maintenance Chart5.3 Maintenance Work Completed

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Routine Maintenance 5.1 Maintenance Schedule

Intercooler (drain lube oil/condensation)

Oil filter cartridge (at each lube oil change)

V-belts (retension or replace if necessary)

Section

3.3#

6.4.3/6.4.4

6.6.1#

6.5.1

6.7.1

#4.2/5.2

6.1.2/3.3.4

6.1.1/ 6.1.2

4.3.1/2/3

6.1.3

6.2.1

#

Industrial enginesThe specified engine maintenance values arepermissible recommended maximums.Depending on usage, reduced maintenanceintervals may be necessary, comply with theunit manufacturer's operating instructions.# Maintenance must only be carried out byauthorised service personnel

Valve clearance

Engine monitoring system, warning system

Intake air cleaner (If available, maintain according to maintenance indicator)

Coolant (additive concentration)

Lube oil (oil change intervals depending on engine use), see TR 0199-99-3002

Injection valve

Battery and cable connectors

Fuel pre-c1eaner/ filter element (cleaning or replace if necessary)

Flexible fuel leak oil lines (replace completely)

Fuel filter cartridge

Operation

Top lube oil up if necessary

r,««<]<'« ««I Coolantpump

Coolant level

check= • adjust= 0 c1ean= • replace= •

Years

~ prior to or during 1st trial run, check 2x daily during the breaking in phase or

when commissioning new and overhauled engines

every 10 hours of operation or daily

Operating hours (OP) every

* When the warning system responds (lamp/horn), the fuel pre-filter must be emptied immediately

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5.1 Maintenance Schedule Routine Maintenance

check= • adjust= 0 c1ean= ... replace= •

prior to or during 1st trial run, check 2x daily during the breaking in phase or whencommissioning new and overhauled engines

every 10 hours of operation or daily

In hours of operation (HO) everyYears

Industrial enginesThe specified engine maintenance valuesare permissible recommended maximums.Depending on usage, reduced maintenanceintervals may be necessary, comply with theunit manufacturer's operating instructions.# Maintenance must only be carried out by

authorised service personnel Section

9.2

#

I

Page 2 of 2

#

OperationInjection valve

check= • adjust= 0 c1ean= ... replace= •

every 10 hours of operation or daily

In hours of operation (HO) every

Additions and modificationsfor engines with EPA approval

The specified engine maintenance values arepermissiblerecommended maximums. Depending on usage, reduced

.-----------------------------1 maintenance intervals may be necessary, comply with the

unit manufacturer's operating instructions.# Maintenance must only be carried out by authorised

service personnel Section

Max. permissible reference times in operating hours (HO) every

prior to or during 1st trial run, check 2x daily during the breaking inphase or when commissioning new and overhauled engines

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Routine Maintenance 5.2 Maintenance Chart

The maintenance chart shown on this page issupplied as a self-adhesive label with eachengine. It should be affixed where it can beseen clearly on the engine or drivenequipment.

Check that this is the case.

If necessary, ask your engine or equipmentsupplier for a fresh supply of labels.

Routine work should be carried out accordingto the schedule in 5.1.

~~:.. ~.. ' 125-.' "k~ 2000~

~r~ a-~ 1500

~~~.

0297 9901 [JJ

2012 ®DEUTZ ~~..~~ __

Stop the engine before carry­ing out any maintenance work.

5.2 Maintenance Chart Routine Maintenance

The maintenance chart shown on this page is supplied as a self-adhesive label with each engine. It should be affixed where it can be seen Eclearly on the engine or driven equipment.Check that this is the case.If necessary, ask your engine or equipment supplier for a fresh supply of labels.Routine work should be carried out according to the schedule in 5.1.

Kraftstoff-Vorfilter WartungFuel prefilter MaintenancePrefiltre combust. EntretienPrefiltro combust. Mantenimiento

2012*Filterelement mindestens

jahrlich wechseln!Change filter element atleast once a year!Remplacer l,element filtrant

~~~bi~sel~ie~~n~~rfftriante,por 10 menos, una vez al ano.

We move your world.www.deutz.de

Wasser nach Aufleuchten derKontrollleuchte ablassen.Drain water when pilot lamplights up.f~~~~~~~lii~~~~rsque la lampeEvacuar el agua al encenderselaluztestigo.

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Routine Maintenance 5.3 Maintenance Work Completed

C'I')ooC'\I@

Cp. hours Date Signature/stamp Cp. hours Date Signature/stamp

50-150* -

125 250

375 500

625 750

875 1000

1125 1250

1375 1500

1625 1750

1875 2000

2115 2250

2375 2500

2625 2750

* following commissioning of new and overhauled engines.

Duly completed maintenance jobs can be recorded and signed off in the above chart.

5.3 Maintenance Work Completed Routine Maintenance

Op. hours Date Signature/stamp Op. hours Date Signature/stamp

2875 3000

3125 3250

3375 3500

3625 3750

3875 4000

4125 4250

4375 4500

4625 4750

4875 5000

5125 5250

5375 5500

5625 5750

Duly completed maintenance jobs can be recorded and signed off in the above chart.(V')

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Routine Maintenance 5.3 Maintenance Work Completed

II

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Op. hours Date Signature/stamp Op. hours Date Signature/stamp

5875 6000

6125 6250

6375 6500

6625 6750

6875 7000

7125 7250

7375 7500

7625 7750

7825 8000

8125 8250

8375 8500

8625 8750

Duly completed maintenance jobs can be recorded and signed off in the above chart.

5.3 Maintenance Work Completed Routine Maintenance

Cp. hours Date Signature/stamp Cp. hours Date Signature/stamp

8875 9000

9125 9250

9375 9500

9625 9750

9875 10000

10125 10250

10375 10500

10625 10750

10825 11000

11125 11250

11375 11500

11625 11750

Duly completed maintenance jobs can be recorded and signed off in the above chart.

I:

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Routine Maintenance 5.3 Maintenance Work Completed

I

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cp. hours Date Signature/stamp cp. hours Date Signature/stamp

Service and Maintenance

6.1 Lubrication System6.2 Fuel System6.3 Cooling System6.4 Combustion Air Filter6.5 Belt Drives6.6 Adjustments6.7 Accessories

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Service and Maintenance

I 6.1.1 Oil Change Intervals

• The lube oil is changed for the first time 50­150 hours of operation following commis­sioning or recommissioning or followingrepairs

• The lube oil change intervals are dependenton:- Lube oil quality- Fuel sulphur content- The engine application

• If the oil change times are not achievedwithin a year, the oil must be changedat least once a year.

• The table refers to the following conditions:- For diesel fuel: Sulphur content max.

0.50/0 by weight.-Continuous ambient temperature downto -10°C (+14 OF).

• In the case of fuels- with> 0.5 to 1 % sulphur content

or- Continuous ambient temperatures

down to -10°C (+14 OF)or

- with biological diesel fuels to DIN51606-FAME, the oil change inter­vals must be halved.

• In the case of fuels with a sulphur contenthigher than 1%, ask the relevant

~ Service representative.ooN Change the oil with the engine off but still@ warm (lube oil temperature approx. 80°C).

6.1 Lubrication System

6.1 Lubrication System Service and Maintenance

6.1.1.1 Lube oil change intervals for industrial and marine engines

Lube oil arade

Deutz lube oil quality class DQCI DQC II DQC III

ACEA-specfication E2-96 E3-96/E5-02 E4-99

API-specification CF/CF-4 CG-4/CH-4 -

Worldwide specification - DHD-1 -

special DEUTZ release list - - Enclosure 1

Standard lube oil code for building EO... EO...C -

equipment and nonraod vehicles EO...A, EO...B

Engine Engine version Lube oil change intervals in op. hours

series Oil use Oil use Oil use

normal high normal high normal high

2012 All engines except for: 250 500 500

BF4M2012C P > 95 kW - - 500

BF6M2012C P > 143 kW, from nonroad stage II - - 500

at cylinder bore 101 mm or 98 mm with MV system

BF6M2012C P > 135 kW, from nonroad stage II - - 500

at cylinder bore 98 mm with mech. injection system

Other engines from nonroad stage II - 500 500

eng. in harv. machines, block-typethermal power stat., gensets* - - 500

*Gensets as referred to here are units operating in parallel with the mains / with each other.

Emergency power units are dealt with in TR 0199-99-1126. -q­ooN

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Service and Maintenance 6.1 Lubrication System

Schmierol-QualiUit

I 6.1.1.2 Oil change intervals for vehicle engines

Deutz lube oil quality class DQCI DQC II DQC III

ACEA specification E2-96 E3-96/E5-02 E4-99

API s ecification CF/CF-4 CG-4/CH-4

Euro II and Euro III exce t for:

40000

30000

4000040000

30000

30000

40000

30000

20000

20000

2000020000

3000030000

20000

15000

Enclosure 1

DHD-1

Lube oil change intervals in km

20000m

> 143 kW from Euro II at cylinderbore 101 mm with or 98 mm with MV s stem

> 135 kW from Euro II at cylinderr mm wi h m h ni I in' i n

> 95 kW from Euro II

> 135 kW from Euro II at cylinder bore 98 mmwith mechanical in"ection s stem

Euro IEuro II and Euro III exce t for:

> 135 kW from Euro II at cylinderbore 98 mm with mechanical in"ection s stem

> 95 kW from Euro II

> 143 kW from Euro II at cylinderbore 101 mm with or 98 mm with MV s stem

> 143 kW from Euro II at cylinderbore 101 mm with or 98 mm with MV s stem

e ial DEUTZ relea e

2012 __E.......uLL...:!ro~I _Euro II and Euro III exce t for:

Engine version

worldwide specification

Longdistancetraffic

Application

Localtraffic

Sitevehicles/busses

If, for vehicle engines, lube oil change intervals are determined by operating hours, the lube oil change intervals indicated in table 4.1. for "Oiluse under normal duty" will apply.

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6.1 Lubrication System

6.1.2 Check Oil Levell ChangeEngine Oil

6.1.2.1 Check Oil Level

Service and Maintenance

6.1.2.2 Engine Oil ChangeE

OIL

?•

• Ensure that the engine or vehicle is in a levelposition.

• Engine warm:Shut engine off, wait for 5 minutes and checkoil level.

• Engine cold:Check oil level.

• Remove the oil dipstick.• Wipe the dipstick with a non-fibrous, clean

cloth.• Insert it to the stop and remove again.• Check the oil level, and if necessary, top up to

the "MAX" mark.- If the oil level is only just above the "MIN"mark, more oil must be added.

The level must not fall below the "MIN" mark.

• Run engine until warm.• Ensure that the engine or vehicle is in a level

position.- Lube oil temperature approx. 80°C.

• Switch off the engine.

• Place oil tray under the engine.• Unscrew oil drain screw.• Drain oil.• Screw oil drain screw in with new seal ring

and tighten. (Tightening torquesee 9.2).

• Pour in lube oil.- For grade / viscosity, see 4.1- For quantity, see 9.1.

• Check oil level, see 6.1.2.1.

&........ ...........•...•..........•.... Caution when draining hot oil: Risk of, scalding!• . Do not let used oil run into the soil but

collect it in a container! gDispose ofthis in accordance with environmental 0

regulations! ~

Service and Maintenance

I 6.1.3 Replace Oil Filter

6.1 Lubrication System

J• With attached locking piston:

Undo tensioning screws and removetensioning clamps downwards.

• Undo the lube oil filter cartridge using acommercial tool and spin off.

• Catch any escaping oil.

• Clean any dirt from the filter carrier sealingsurface.

• Lightly oil the rubber gasket of the new lubeoil filter cartridge.

• Manually screw in the new cartridge untilthe gasket is flush.

• Tighten the lube oil filter· cartridge withanother half-turn.

• If locking piston is available:Position tensioning clamps and tighten withtensioning screws.

• Check oil level, see 6.1.2.

• Check oil pressure, see 3.3.1.

• Check lube oil filter cartridge seal for leaks.

Caution is required in the case ofhot oil: Risk of·scalding!

6.1 Lubrication System

6.1.4 Clean I ReplaceOil Filter (Cup)

• Switch off the engine.• Loosen lube oil filter cover 1 and unscrew

in an anticlockwise direction, emties itselfthe system automatically (drain valve).

• Carefully loosen paper filter cartridge 3upwards from the guide 4.

• Catch any escaping oil.• Replace paper filter cartridge 3.• Clean any dirt from the sealing surface of

the filter carrier and lube oil filter cover 1and fromb the guide 4.

&..•••...•.•.••....................•......•..•...•....................•........•....•............... Caution is required in the case

'

of hot oil:....... Risk of scalding!•

Service and Maintenance

• Replace and lightly oil the rubber gasket 2.• Carefully insert new paper filter cartridge 3

into guide 4.• Tighten lube oil filter cover 1 in a clockwise

direction (25 Nm).• Start engine.• Check oil level, see 6.1.2.• Check oil pressure, see 3.3.1.• Check lube oil filter attachment for leaks.

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Service and Maintenance

I 6.2.1 Replace Fuel Filter

6.2 Fuel System

• Close the fuel shut-off valve.

• Undo fuel filter cartridge with commercialtool and spin off.

• Catch any escaping fuel.

• Clean any dirt from the filter carrier sealingsurface.

• Apply light film of oil or diesel fuel to therubber gasket ofthe new fuel filter cartridge.

• Manually screw in the new cartridge untilthe gasket is flush.

• Tighten the fuel filter cartridge with a finalhalf-turn.

• Open fuel shutoff valve.

• Check for leaks.

The fuel system does notneed tobebled.

Keep naked flames away when working on thefuel system. Do not smoke!

6.2 Fuel System

6.2.2 Clean I ReplaceFuel Oil Filter (Cup)

• Switch off the engine.• Loosen fuel oil filter cover 1 and unscrew in

an anticlockwise direction, emties itself thesystem automatically (drain valve).

• Carefully loosen paper filter cartridge 3upwards from the guide 4.

• Catch any escaping oil.• Replace paper filter cartridge 3.• Clean any dirt from the sealing surface of

the filter carrier and fuel oil filter cover 1 andfromb the guide 4.

&Keep naked flames away when

...•••.

..•••...••..•.......•....,•...•.•..•...•••.•......•...•.•... working on the fuel system. Donot smoke!•

Service and Maintenance

• Replace and lightly oil the rubber gasket 2.• Carefully insert new paper filter cartridge 3

into guide 4.• Tighten fuel oil filter cover 1 in a clockwise

direction (25 Nm).• Start engine.• Check fuel oil filter attachment for leaks.

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Service and Maintenance

• 6.2.3 Clean I purge or change fueliii pre-filter

6.2 Fuel System

6.2.4 Bleed Fuel Systemwith Fuel Pre-filter

Clean (purge) - remove water:• Turn off engine or, in the case of a change-

over filter, switch over to the other filter.• Close the fuel stopcock or supply. (ifavailable)• Open the bleed screw 1 on the cover 2• Place the fuel collector underneath the fuel

pre-filter.• Empty water and dirt from the bowl 6 by

opening (press in and tum slightly withoutusing force) the drain cock 8 and close thedrain cock 8 again

• Close the bleed screw 1 on the cover 2 again• Bleed the fuel pipe according to instructions,

see 6.2.5 opposite~ Changing the filter element 5:g Change at least once a year or as required (dropN@

in performance also after purging)• Tum off the engine or switch to other filter in

case of changeover filter• Close the fuel stopcock or supply (if available)• Loosen the cover screws 3 diagonally• Remove the cover 2• Remove the spring cassette 4• Remove the filter element 5 from the bracket• Insert new filter element 5• Place spring cassette 4 on the element• Check that the cover seal is fit properly in the

cover 2 and check for damage (change ifnecessary)

• Tighten the cover 2 with the screws 3diagonally (torque 6 Nm)

• Check the cover 2 for proper fit and leaks• Bleed the fuel system, see 6.2.4.

~ The connection of a warning system~ (lamp/horn) via contacts 7 is specified.Immediate maintenance is necessary when thewarning system is triggered.

.&Naked flames are prohibitedwhen

,•...•• .... .... working on the fuel system! Donot smoke!

•••••••••• <. Dis~se of old fuel in an environ-mentally friendly way!

• Place fuel collection container beneath thefuel pre-filter.

Bleed:• In the event of re-commissioning, following

maintenance work or if the tank has beenrun empty, the fuel system must be bled.

• Bring engine regulator into stop position.• Position fuel collection container beneath

filter housing 8 / pressure maintenancevalve 9.

• Open fuel shut-off valve, pressuremaintenance valve 9, bleeder screw 1.

• Turn engine over with starter (max. 20 sec.)until bubble-free fuel escapes from bleederscrew 1 and pressure maintenance valve9.

• Firmly tighten bleeder screw 1and pressuremaintenance valve 9, see 6.2.5..

• Bring engine regulator into start positionand start.

• Check for leaks after starting the engine.

.&' Keep naked flames away when

,'. .••...... . working on the fuel system. Do, ., '.. not smoke!

../" ....••••~.•~.. Dispose ofused fuel in an envi­ronmentally-friendly manner!

6.2 Fuel System

6.2.5 Bleed Fuel Systemwithout Fuel Pre-filter

Service and Maintenance

6.2.6 Clean/Replace Fuel Pre-Filter,Filter Element

• Bring engine regulator into stop position.• Open fuel shut-off valve.• Loosen pressure maintenance valve 9.

Collect any escaping fuel and dispose ofthis in an environmentally-friendly manner.

• Turn engine over with starter (max. 20 sec.)until bubble-free fuel escapes from pressuremaintenance valve 9.

• Tighten pressure maintenance valve 9.• Bring engine regulator into start position

and start.• Check for leaks after starting the engine.

A Keep naked flames away when

.•..................,.•. ,'.,...••.•••......•......•......... ,. working on the fuel system. Do• not smoke!

III .... Dispose of used fuel in an envi-ronmentallv-friendlv manner!

Clean/Replace:• Close the fuel shut-off valve.• Place fuel collection container beneath the

fuel pre-filter.• Loosen the drain screw 7+9 and drain fuel.• Turn the filter element housing 4 with gasket

3 and filter element 3 anti-clockwise andremove.

• Clean any dirt from the sealing face of thefilter carrier and filter element housing 4and sludge chamber 5 and filter element(replace if necessary).

• Insert new round sealing rings 2+3+6.• Screw in filter element housing 4 and filter

element (max. torque 25 -5 Nm).• Tighten the drain screw 7+9

• Open fuel shut-off valve.• Bleed system• Check for leaks after starting the engine.

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Service and Maintenance 6.2 Fuel System

6.2.7 Clean/ReplaceNent FuelPre-Filter, Filter Element

Clean:• Close the fuel shut-off valve.• Place fuel collection container beneath the

fuel pre-filter.• Loosen the drain screw 5 and drain fuel/

water.• Turn filter cartridge 2 and dirt trap 3

anticlockwise and remove.• Turn dirt trap 3 anticlockwise and remove.

Empty emulsion into the fuel collectioncontainer and clean the dirt trap 3.

• Screw the filter cartridge 2 and dirt trap 3together. Wet the filter cartridge with fuel,wet the sealing surfaces 8 slightly with oil.

~ • Mount clockwise.ooN@

• Open the fuel shut-off valve and bleed thesystem.

• Check for leaks after starting the engine.

Replace:• Replace defective filter cartridge 2.• Clean any dirt from the filter carrier 1sealing

surface 8.• Wet the filter cartridge 2 with fuel, wet the

sealing surfaces 8 slightly with oil.• Mount the filter cartridge 2 and dirt trap 3

clockwise.• Open fuel shut-off valve.• Check for leaks and vent the system after

starting the engine.

AWork may only be performed on

.••....••....••.....•,...••.....•.,.••,.,..,•.,.•.'.'.••.•..•...............•,.....•....•.•..•........, the fuel system with the engineswitched off.

" ..... No naked flames! Do notsmoke!Dispose of waste fuel in anenvironmentally-friendlymanner.

-q­ooN@

Service and Maintenance

I 6.3.1 Cleaning Intervals

6.3 Cooling System

6.3.2 Clean Cooling System

• The amount of contamination in the coolingsystem depends on the engine application.

• Oil and fuel residues on the engine increasethe risk of contamination. Therefore payspecial attention to leaks if the engine isused in dusty environments.

• Serious contamination occurs, for example:- on construction sites where there is a highlevel of air-borne dust.- in harvesting applications where there arehigh concentrations ofchaff and choppedstraw in the vicinity of the machine.

• Because applications vary, cleaningintervals have to be determined from caseto case. The cleaning intervals given in thetable below can be used as a guide.

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Checking or cleaning intervals

Guideline Engine applicationvalues OH

2000 Ships, electrical modules in

enclosed areas, pumps.

1000 Vehicles on paved roads

500 Tractors, fork-lift trucks,

drivable electric units.

250 Vehicles on construction sites

and unpaved roads, construc-

tion machines, compressors,

underground mining units.

125 Agricultural machines, tractors

in harvesting applications.

• External cooling system: Clean accordingto cooling system manufacturer's speci­fications.

6.3 Cooling System

6.3.3 Drain Cooling System

Service and Maintenance

6.3.4 Filii Bleed Cooling System2012

Standard EngineE

• Position a collecting pan beneath screwplug 1.

• Remove screw plug 1 at crankcase.• Drain coolant.• Tighten screw plug 1 again.• If screw plug 1 is not accessible,

drainage can be carried out at the engineradiator (coolant channel).Fill / bleed cooling system see Chapter 6.3.4

Cautionwhen draining hotcoolant:Risk of scalding! Collect coolanton draining.Dispose of this in accordance withenvironmental regulations!

• Open radiator cap item 1.• Loosen vent hose item 2.• Fill coolant item 1b in up to the "MAX" mark or

filling limit (if fitted, system heater valve mustbe open).

• Connect vent hose, item 6, + tighten screwplug item 4.

• Close radiator cap item 7.• Start engine and warm up until thermostat

opens.• Switch off the engine.• Check coolant level when engine is cold, and

top up if necessary.• Close radiator cap item 1.

Bleed• External cooling system: According to cooling

system manufacturer's specifications.

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Service and Maintenance

I 6.4.1 Cleaning Intervals

6.4 Combustion Air Filter

• The amount of dirt in the combustion airfilter depends on the amount of dust in theair and the size of the airfilter used. If a highlevel of dust is anticipated, a cyclone-typepre-cleaner can be fitted in front of thecombustion air filter.

• Cleaning intervals must therefore bedetermined from case to case.

• If dry type air filters are used, cleaningshould only be carried out according to theservice indicator or service switch.

• Filter servicing is needed when:- Service indicatorthe red signal 1is fully visible when the engineis off.

- Service switchthe yellow pilot lightcomes on when the en­gine is running.

• After carrying out service work, press thereset button on the service indicator. Theservice indicator is now ready for operationagain.

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6.4 Combustion Air Filter

6.4.2 Emtying Cyclone TypePrecleaner

Service and Maintenance

6.4.3 Clean Oil Bath Air Filter

• Undo wing nut 1 and remove cover 2.• Remove collector bowl 3 from lower section

4 and empty. Clean leaves, straw and otherforeign matter from lower section ofprecleaner.

• Reposition collector bowl 3 onto lowersection 4, fasten cover 2 in place by tight­ening wing nut 1.

• Turn engine off and wait about 10 minutesfor the oil to drain from filter housing 1.

• Loosen snap clips 2 and remove oil cup 3with filter element 4; if necessary, loosenfilter element with the aid of a screwdriverat the separating point. Do not damagerubber gasket 5!

• Remove dirty oil and sludge. Clean oil cup.• Clean filter element 4 in diesel fuel and

allow to drip-dry thoroughly.

• Clean filter housing 1 if very dirty.• Inspect and replace rubber gasket 5 and 6

if necessary.• Fill oil cup with engine oil up to the mark

(arrow) (for viscosity, see 4.1.2).• Refit oil cup and element to filter housing

and secure with snap clips.

Never fill collector bowl with oil. Replacecollector bowl if damaged.

Never clean filter with gasoline.Dispose of old oil in accordance 3with environmental regulations! ~

@

Service and Maintenance 6.4 Combustion Air Filter

• 6.4.4 Dry Type Air FilterII Dust Discharge Valve

• Empty dust discharge valve 1 by pressingapart lips of discharge slot as indicated byarrows.

• Clean discharge slot from time to time.

• Remove any caked dirt by pressing togetherthe upper section of the valve.

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Filter Cartridge

• Undo clip fasteners 1.• Take off hood 2 and remove cartridge 3.• Clean cartridge (replace at least once a

year)• Clean cartridge 3.

- Using dry compressed air (max. 5 bar),blowout from inside outwards,

or- Tap out (in emergencies only). Do not

damage the cartridge, or- Wash out according to manufacturer's

specifications.• Check paper filter (light showing through)

and gaskets for damage. Replace ifnecessary.

• After five filter services or after two years atthe latest, replace safety cartridge 4 (neverclean!).To do so:- Undo hex nut 5 and remove cartridge 4.-Insert new cartridge, re-install hex nut and

tighten.• Install cartridge 3, replace hood 2 and do

up clip fasteners 1.

Never clean filter cartridge withgasoline or hot fluids!

6.5 Belt Drives

6.5.1 Check V-belts2012 Standard

Service and Maintenance

2012 with Ribbed V-belt E

• Visually inspect entire V-belt for damage.• Replace damaged V-belts.• After installing new belts, run engine for 15

minutes, then check belt tension.• To check the tension of the V-belt, use a

tension gauge (see 9.3).- Place indicator arm 1 into gauge.- Position guide 3 on V-belt 2, midwaybetween the pulleys, with flange 3 onbottom of gauge against the edge of belt.- Push slowly on the black pad 4 at rightangles to V-belt 2 until the spring is heardor felt to trigger.

-Carefully raise the gauge without changingthe position of indicator arm 1.

- Read off the value where the indicator arm1 intersects scale 5 (arrow) and readindicator arm 1 off. For settings, see 9.1.

- If necessary, retension belt and measureagain.

Check, tension and change V­belts only with the engine off. Ifnecessary, reinstall V-belt

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Service and Maintenance 6.5 Belt Drives

I 6.5.2 Tension V-beltsCoolant I Fuel Pump

• Loosen screws 1and2.• Press fuel pump 3in direction ofarrowuntil the

correctV-belttension hasbeen achieved.• Tighten screws 1and 2again.

6.5.3 Replace V-beltsCoolant I Fuel Pump

• Loosen screws 1and2.• Press fuel pump 3in direction ofarrow.• RemoveV-beltand position newbelt.• Press fuel pump counterto direction ofarrow

until thecorrectV-belttensionhasbeenachieved.• Tighten screws 1and2again.

6.5.4 Replace V-belts

• Presstension roller indirectionofarrowuntil theribbed V-belt is free.

• First remove ribbed V-belt from the smallestroller.

• Position newribbed V-belt.• Presstension rollercountertodirectionofarrow

until the ribbed V-belt is tensioned.

Check, tension and change V­belts only with the engine off. Ifnecessary, reinstall V-belt guard.

A Check whether ribbed V-belt isilipositioned correctly in its guide.

6.5 Belt Drives

6.5.5 Tension V-beltsAlternator

• Loosen screws 1, 2 and 4.• Adjust alternator 5 in direction of arrow by

turning screw 3 until correct V-belt tensionis achieved.

• Retighten screws 1, 2 and 4.

Service and Maintenance

6.5.6 ReplaceV-beltsAlternator

• Loosen fuel pump V-belt, see 6.5.3• Loosen screws 1,2 and 4.• Adjust screw 3 until V-belt can be removed.• Position new belt.• Adjust screw 3 until the correct V-belt

tension has been achieved.• Retighten screws 1, 2 and 4.• Tension fuel pump V-belt, see 6.5.4.

E

Check, tension and change V­belts only with the engine off. Ifnecessary, reinstall V-belt guard.

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Service and Maintenance

I. 6.5.7 Wedge rib V-belts wear limitexamine.

6.5 Belt Drives

• Wear limit of the wedge ribV- belt as followsexamine:

• Distance between the nose of the flexibiliticlamping arm and the notice of the firmtension adjuster housing examine.

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• If "a" is smaller than 3 mm, then the wedgerib V- belt is to be exchanged

6.6 Adjustments Service and Maintenance

Ii

-q­ooN@

Service and Maintenance

6.6.1 Check Valve Clearance,Adjust if Necessary

6.6 Adjustments

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• Loosen ventilation valve and swing to theside.

• Remove the cylinder head cover.• Position crankshaft as per schematic, see

6.6.1.1.• Before adjusting valve clearance, allow

engine to cool down for at least 30 minutes.The oil temperature should be below 80 cC.

• Check valve clearance 1 between rockerarm / tappet contact face 2 and valve 3 withfeeler gauge 6 (there should be only slightresistance when feeler blade is inserted).For permissible valve clearance, see 9.1.

• Adjust valve clearance if necessary:- Release locknut 4.- Use screwdriver 7 to turn setscrew 5 sothat the correct valve clearance 1 isattained after locknut 4 has been tigh­tened.

• Check and adjust valve clearance on allcylinders.

• Reinstall cylinder head cover (with newgasket if necessary).

• Swing ventilation valve into position andfasten.

6.6 Adjustments

6.6.1.1 Valve Clearance AdjustmentSchematic

Service and Maintenance

E• Crankshaft Position 1:

Turn crankshaft until both valves in cylinder1 overlap (exhaust valve about to close,inlet valve about to open). Adjust valveclearance according to schematic (markedin black). Mark respective rocker arm withchalk to show that adjustment has beencarried out.

• Crankshaft Position 2:Turn crankshaft one full revolution (360°).Adjust valve clearance according toschematic (marked in black).

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Service and Maintenance 6.7 Accessories

I 6.7.1 Battery6.7.1.1 Check Battery and

Cable Connections

1©125 89510

6.7.1.2 Check Electrolyte Level 6.7.1.3Check Electrolyte Density

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• Keep battery clean and dry.

• Undo dirty clamps.

• Clean terminal posts (+ and -) and clampsof the battery, and grease with acid-freeand acid-resistant grease.

• When reassembling, ensure that clampsmake good contact. Tighten clamp boltshand-tight.

• Remove sealing caps 1.

• If testers 2 are present:Electrolyte level should reach the base ofthese.

• Without testers:The electrolyte level should be 10-15 mmabove the top of the plates.

• If necessary, top up with distilled water.

• Screw sealing caps back in .

• Measure the electrolyte density of individualcells with a commercial hydrometer.The hydrometer reading (see table onfollowing page) indicates the battery's stateof charge. During measurement, thetemperature of the electrolyte should pref­erably be 20°C.

6.7 Accessories Service and Maintenance

EElectrolyte density

in [kg/ I] in [OBe (Baume scale)*] Charge status

Normal Tropical Normal Tropical

1.28 1.23 32 27 well charged

1.20 1.12 24 16 semi-charged, re-charge

1.12 1.08 16 11 discharged, immediately charge

* Measurement of electrolyte density in ° Be(Baume scale) is out of date and rarelyused today.

...

&..............................•........ The gases emitted by the battery, .. . are explosive! Keep sparks and.. .. naked flames away from the

battery!Do not allow battery acid to come

into contact with skin or clothing!Wear protective goggles!Do not rest tools on the battery!

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Service and Maintenance 6.7 Accessories

I 6.7.2 RotaryCurrentAltemator

Notes on the three-phase system:• Never disconnect the cables between

battery, alternator and regulator while theengine is running.

• If, however, it is necessary to start andoperate the engine without the battery,disconnectthe regulator from the alternatorbefore starting.

• Be sure not to confuse the battery terminals.

• Replace defective charge pilot lamp bulbimmediately.

• When cleaning the engine: Do not spraythe alternator with a direct jet of water/steam!Allow the engine to run warm so that theremaining water evaporates.

• The habit of touching a lead against theframe to check whether it is live must underno circumstances be used with three-phaseelectrical systems.

• In case of electric welding, connect theground terminal on thewelderdirectlyto the piece being welded.

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6.7.3 Transportation Shackles

• Only use proper lifting gear whentransporting the engine.

.& Use only the correct lifting gear!

Faults, Causes and Remedies

7.1 Fault Table

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Faults, Causes and Remedies

• Faults can frequently be attributed to the factthat the engine has been incorrectly operatedor not serviced.

• Each time a fault occurs, check whether alloperating and servicing regulations have beencomplied with.

• A corresponding fault table can be foundon the opposite page.

• If the cause of a fault cannot bedetermined, oryou are unable to remedyafaultyourself, then please contact yourDEUTZ Service representative.

Before starting, make sure that nobody is stand­ing in the immediatevicinityoftheengineordrivenmachine.In the event of repair work:

&Caution: If the speed regulatorhas been removed, the engine

, must not be started under any• circumstances.

Disconnect the batteryl

7.1 Fault Table Faults, Causes and Remedies

Faults MeasuresEngine does not start or is difficult to start (Starting speed is not achieved on starting) Check P

Engine starts, but runs irregularly or fails Adjust EEngine becomes excessively hot. Temperature warning system responds Replace W

Engine output is deficient Clean R

Engine does not run on all cylinders Top up AEngine oil pressure is non-existant or excessively low Bleed L

Engine oil consumption excessive

Engine smokes - blue

- white

- blackCause Section

• <i iiii ········Iii>i> Not declutched (where possible) Engine Operation p

• i iii> i>ii ,i • iBelow starting limit temperature Pi >

• i.·> • ii iI •• i ... Engine shut-off lever still in stop position (shutoff magnet defective) Piii >iiii • i • ii> >iiI Oil level too low A)i ... i

• • ii.i • • Oil level too high Sii • • • >i Excessive inclination of engine ~

• ii ii iiii Adjust throttle to half actuation travel ~ii.

········iiii Combustion air> iii • • i • Air cleaner clogged / turbocharger defective ~>i • • ii • Air cleaner service switch / indicator defective P> i

•••••••

••••••••••••••••••••• i • CPO* defective (connection line leaks) P.·.·······.·i

ii • ••••••••••••••••••••

>i

••••••••••••••

• Charge air line leaking ~i» •

••••••••••••••••••••••••

ii i i Coolant pump defective Cooling system~

> • i i • Intercooler soiled ~i >.i

• iii i Coolant heat exchanger soiled ~< .·..··i Cooling fan defective, torn or loose V-belt P/W• • • • • i

(fuel pump in belt drive)

• • i/ >Cooling air temperature rise / heating short circuits -----p-

• i> i>Battery defective or discharged Electrics ~

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*CPO =Charge pressure-dependent full-load stop Table 1of 2

Faults, Causes and Remedies 7.1 Fault Table

Faults

Engine does not start or is difficult to start (Starting speed is not achieved on starting)

Engine starts, but runs irregularly or fails

Engine becomes excessively hot. Temperature warning system responds

Engine output is deficient

Engine does not run on all cylinders

Engine oil pressure is non-existant or excessively low

Engine oil consumption excessive

Engine smokes - blue

- white

- black

Measures

Check

Adjust

Replace

Clean

Top up

Reduce

PE

W

R

A

S

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Cause SectionCable connections, starter, electrical circuit loose or oxidised Electrics P

Starter defective or pinion does not engage P

Incorrect valve clearance Engine EInjection line leaks P

Ventilation line blocked (coolant heat exchanger) P / RSheathed glow plugs defective P

Injection valve defective P / WAir in the fuel system P / WFuel filter / fuel pre-cleaner soiled P / R/ WOil filter defective W

&++--_In_co_rre_c_t_e----.:ng:::....in_e_l_ub_e_o_i_1S_A_E_c_la_s_s_o_r---'-q_ua_li-=.ty ---I Operating media f--_W_-----iFuel quality not as per operation manual P / WCoolant deficiency P / A

Table2of2

8.1 Preservation

Engine Preservation

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Engine Preservation 8.1 Preservation

1 8.1 Preservation

If the engine is to remain idle for an extendedperiod of time, it is necessary to take protec­tive measures to prevent the formation ofcorrosion. The preservative measures de­scribed here will protect the engine for up toapprox. 6 months. The procedure will have tobe reversed before the engine isrecommissioned.

• Anti-corrosion oils to specification:- MIL-L 21260B- TL 9150-037/2- Nato Code C 640 / 642

• Recommended cleaning agent to removepre servatives:- Petroleum benzine (hazardous materials classA3)

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Preserve engine:• Clean engine (poss. with cold cleaner).

Radiator cleaning, see 6.3.2.• Run engine until warm, then turn off.• Drain engine oil, see 6.1.2, and fill with anti­

corrosion oil.• Drain coolant, see 6.3.3.• Top up anti-corrosion agent, see specifica­

tions.• Clean oil bath air filter if necessary, see

6.4.3, and top up anti-corrosion oil.• Drain fuel tank.• Make up a mixture of 90 % diesel fuel and

10 % anti-corrosion oil, and refill fuel tank.• Allow the engine to run for approx. 10 mins.• Switch off the engine.• Manually turn the engine over several times.

When turning over with starter, set shutofflever to stop position.

• Remove V-belts and store in wrapped con­dition.

• Spray grooves on V-belt pulleys 2 with anti­corrosion spray.

• Drain anti-corrosion agent, see 6.3.3.

• Lightly preserve coolant filler neck and sealwith cap.

• Seal intake ports and exhaust ports.

Remove engine preservation:• Remove anti-corrosion agent from

grooves in V-belt pulleys 2.

• Install V-belts. Retension after briefoperation if necessary, see 6.5.

• Remove covers from intake port 3 andexhaust port 4.

• Disconnect coolant inlet and outlet neckcovers, remove protection and connect tocooling system.

• Top up coolant, see 6.3.4.System must be bled.

• Commission engine

Technical Specification

9.1 Engine Specifications and Settings9.2 Torque Wrench Settings9.3 Tools

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Technical Specification 9.1 Engine Specifications and Settings

ModelNumber of cylindersCylinder arrangementBoreStroke

Total displacementCompression ratioWorking cycleCombustion systemCharge air coolingDirection of rotationWeight 20121 C including cooling systemto DIN 70020-A [approx.kg]

----------- BF4M 2012 ---------------------- BF4M 2012 C ---------------------- BF6M 2012 C ------------------------- 4 --------------------------------------- 4 ---------------------------------------- 6 -------------------------------------------------------------------- verticalin line -------------------------------------------------

[mm] ---------------------------------------------------------- (2) 101------------------------------------------------------­[mm] ----------------------------------------------------------- 126 --------------------------------------------------------

[cm3] ---------------- 4.04 ----------------------------------- 4.04 ----------------------------------- 6.06 -------------

[E]. ------------------------------------------------------------ 19 --------------------------------------------------------­-------------------------------------------------- Four-stroke diesel -------------------------------------------------------------------------------- with turbocharging and direct fuel injection --------------------------------------------- without --------------------------------- with ------------------------------------ with --------------------------------------------------------------- counter-clockwise -----------------------------------------------

------------------------------------------------- Refer to head-office ---------------------------------------------

Engine output [kW] ------------------ 75 ------------------------------------ 103 ------------------------------------ 155 -------------Max. speed [1 Irpm] ---------------------------------------------------------- 2500 -------------------------------------------------------Valve clearance with cold engine (PTs) [mm] ----------------------------------------- Inlet 0.3 + 0.1 1 exhaust 0.5 + 0.1. --------------------------------------

Valve clearance with cold engine standard [mm] ------------------------------------ Adjustment with special tool, see 6.6.1 ---------------------------------Injector opening pressure [bar] ----------------------------------------------------------- 250 --------------------------------------------------------Start of feed [0CS BTeC] 1). ---------------------------------------------------------

Firing order of the engine -------------- 1-3-4-2 ------------------------------- 1-3-4-2 ----------------------------- 1-5-3-6-2-4 --------V-beIt tension: -------------------------------------------- Pre-tension 1 re-tension 2) ----------------------------------------------------------------------Alternator 1fan [N] ----------------------------------------------------- 450 1300 ± 50. --------------------------------------------------

Fuel pump - coolant pump [N] ----------------------------------------------------- 450 1300 ± 50. --------------------------------------------------

Compressor [N] ----------------------------------------------------- 550 1450 ± 50. --------------------------------------------------

Ribbed V-belt tension spring-loaded tension roller [N] ----------------------------------------------------- 900 1600 ± 50. --------------------------------------------------

1) Engine output, speed, start of delivery are stamped on engine rating plate, etc., see also 2.1.8 2) Re-tension 15 minutes after the engine has been operated under load.oN

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9.1 Engine Specifications and Settings Technical Specification

ModellingCoolant volume20121 CPerm. constant coolant temperatureEngine exhaust, output group IEngine exhaust, output group II-IVThermostat opening commencement atThermostat fully open fromCoolant pre-heatingCoolant pumpFeed pressure inFeed quantity inPower consumption in

LubricationOil temperature in oil panMin. oil pressure when warm(120°C and SAE oil 15 W 40) and low idle

---------- BF4M 2012 ------------------------ BF4M 2012 C ---------------------- BF6M 2012 C ----------------------------------------- Liquid-cooled 1cooling system protection -------------------------------

[ca.Itr.] ---------------- 5,6 ------------------------------------- 5,6 ------------------------------------ 7,3 --------------

[OC] ----------------------------------------------------- max.11 0 6) • --------------------------------------------------­

[OC] ----------------------------------------------------- max. 105 6). --------------------------------------------------[OC] 7). _

[OC] 83 8) . ----------------------------- _

___________________________________________________________ (4 . _

[bar] ----------------------------------------------------------- 9) • --------------------------------------------------------­

[m3 Ih] ----------------------------------------------------------- 9). ---------------------------------------------------------

[kW] ----------------------------------------------------------- 9) ---------------------------------------------------------

------------------------------------------------ Pressure Iubrication --------------------------------------------­[OC] ---------------------------------------------------------- 125 --------------------------------------------------------

[bar] ----------------------------------------------------------- 0,8 --------------------------------------------------------

Oil plate filling quantity without filter [approx.ltr.] -------------- 8.5 3). -------------------------------- 8.5 3). ------------------------------- 12.5 3). ----------­

Oil plate filling quantity with filter [approx.ltr.] ---------------10 3). ----------------------------------10 3). ---------------------------------14.0 3). -----------

3) Approx. values may vary depending on version. The upper oil dipstick mark is always authoritative.4) Only necessary in winter operation, see 3.5.1.5) Engine content without radiator only. Content of external cooling system depending on cooling system version.6) Other output groups have different values, consultation with head office is required.7) In the case of external cooling systems with outlet regulation, the thermostat begins to open at 87°C8) In the case of external cooling systems with outlet regulation, the thermostat is fully open at 102°C9) Consultation with head office is required (differ depending on engine version)

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Technical Specification 9.2 Screw Tightening Torques

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Installation locationPre-tension [Nm] Re-tension [Nm] Total Comments

1. Stage 2. Stage 3. Stage 1. Stage 2. Stage 3. Stage 4. Stage [Nm]

Cylinder head screw 8.5

Rocker arm adjustment screw 21

Foot on flywheel side 187 M16x40 8.8.8 A4 C

Foot on fan side 30 45 187 M16x40 8.8.8 A4 C

Intake manifold 8.5

Exhaust manifold 21

Oil drain screw 50

Injection valve attachment 16 Torx

Injection line attachment 30 M14x1.5

Oil pan (cast) 29

Oil pan (sheet metal) 21

9.3 Tools

TORX

A TORX wrench set is used with engines inthe 2012 series.This system was chosen because of the manyadvantages it offers:• Outstanding accessibility to bolts.• High load transfer when loosening and

tightening.• Almost impossible for socket to slide off

or break, thereby practically ruling out therisk of injury.

TORX tools can be ordered from:

WILBARPostfach 14 05 800-42826 Remscheid

Technical Specification

V-belt tension gauge

26002 0

The V-belt tension gauge can be obtainedunder order number 8115 + 8120 from:

WILBARPostfach 14 05 800-42826 Remscheid

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Knowing it's DEUTZ

DEUTZ has always stood for excellence in motorconstruction, pioneering many developments inthe industry_ As an independent motor manu­facturer, we offer - worldwide - a com­prehensive range of diesel and gas motorsspanning from 4kW to 7,400kW. Our products areperfectly tailored to meet our customers' individualrequirements.

Over 1.4 million DEUTZ motors do their jobreliably allover the world. We are determined topreserve the high standard of performance anddependability of our motors, thus keeping ourcustomers satisfied at all times. Therefore we arerepresented worldwide through anetwork of highlycompetent service partners who will meet theneeds of our customers, wherever they are.

This is why DEUTZ is not only the name for motorswhich pack a lot of inventive genius. DEUTZ alsomeans reliable service and comprehensive supportto enhance your motor's performance.

This index Sales & Service offers you an overviewof the DEUTZ partners in your vicinity, including theproducts for which they are responsible and therange of services provided. But even when no directproduct responsibility is mentioned, your DEUTZpartner will be happy to help you with expert advice.

The Index is constantly updated. Please ask yourOEUTZ service partner for the latest edition.

OEUTZ AG - at your service.

Register Vertrieb & ServiceRegister Sales & ServiceReseau Distribution & ServiceRegistro Red de Distribucion & Servicio

~:~~~~~~~:~~~~~~~:~~~: .

Obtainable from the local service Partner reponsiblefor you or from:

Service

Order-No.: 0312 0806

Order-No.: 0312 0807 (CD-ROM)

OEUTZ AGOeutz-Mulheimer Str. 147-1490-51063 Koln

Telefon: 0049-221-822-0Telefax: 0049-221-822-5358Internet:www.deutz.deE-mail: info@deutz.de

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